Crowned End Winding Support Reduces Generator Wire Fatigue
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Solution Overview
Problem
Conventional end turn supports for generator main field windings are flat, leading to increased radial loads and potential wire movement, which can cause fatigue failures due to the bow string effect, as they do not adequately support the wires under high loads.
Innovation Solution
The implementation of an arcuate wire receipt surface on end turn supports that extend radially from the axis of rotation, providing a crown-like structure to evenly support the wires and reduce movement, thereby addressing the issue of wire fatigue under high loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If flat end turn supports are used, then the structure is simple, but wire movement increases causing fatigue failures
Solution Approach 1:
The patent applies curvature by replacing flat end turn supports with arcuate wire receipt surfaces. The wire support defines an arcuate wire receipt surface that conforms to the curvature of the rotor core, allowing wires to be supported along their entire span rather than at discrete points. This curved geometry eliminates the bow string effect and prevents wire movement that leads to fatigue failures.
2Ease of manufacture
If flat end turn supports are used, then manufacturing is easy, but radial loads increase causing wire fatigue
Solution Approach 1:
The arcuate wire receipt surface distributes radial loads evenly across the wire span by conforming to the rotor core curvature. This prevents concentrated stress points that occur with flat supports, thereby reducing wire movement and fatigue under high radial loads during generator operation.
3Reliability
If arcuate wire receipt surface is used, then wire support effectiveness improves, but device complexity increases
Solution Approach 1:
The patent merges the wire support function directly into the end turn support structure by defining the arcuate wire receipt surface as an integral part of the wire support. This integration eliminates the need for separate wire support components while providing effective continuous support along the wire span, thus improving reliability without significantly increasing overall device complexity.
Data Source
AI summary
An end turn support for a generator includes a wire support. The wire support extends along an axis in a radial direction from an axis of rotation. The wire support defines an arcuate wire receipt surface.